Our company is based on rebuilt turbocharged cars intake manifolds unique designing and producing out of 2 component epoxy resin impregnated carbon fiber.
Every planning starts with an optimised airflow-simulation, where our purpose is to deliver the highest amount of air into the engine on the shortest and fastest way without causing any unnecessary airflow.
But why better the carbon composites?
Carbon fiber composite parts have several advantages comparing them to metal parts. They are lightweight, very strong, not thermal conductivity, corrosion resistant and the most important for us is that composites resist dynamic strain better, in our case its a pulsing motion which comes from the periodically changing pressure and vacuum (endless endurance). The carbon fibre structure lends a unique appearance.
Our Vacuum infusion technology:
We are laying different weavings of carbon fibre layer by layer
on each other dry, based on a lot of thought of a layer plan. Every kind of multi axial roving resist a different kind of stress. The inside layer is a hybrid aramid-carbon fibre fabric which counterbalances the enlargement of the surrounding matrix-resin due heat. On the inner layer we apply a tearing-fabric and it is followed by a net which ensures the even distribution of the vacuum and the matrix substance. On the top we place a resin introduction pipe.
The Vacuum Infusion Process or is one of a closed mold processes. It distinguishes itself by being the only process that utilizes only atmospheric pressure to push the resin into the mold cavity. The mold cavity is a one-sided mold with bagging film being utilized for the “B” side. there are only three variables affecting the flow of the resin: permeability of the laminate, viscosity of the resin, and pressure differential in the cavity in relation to atmospheric pressure. If all three of these variables are unchanged, then the infusion process will consistently flow the same way with every injection for a given part.
so at the end we put a bagging material over the part and then we seal it off with kind of a glue which is similar to a yellow chewing gum i would say.
then we need to pressurize and heat to consolidate for having the right strength and the right properties.
As you can see it is a very complex technology, there are many types of weaves and different phylosophies how to apply them. Its little bit of a black art really and really lessons learns what kind of phylosophies you are working towards.
I'd say we have a quite good experience and we can create a stream lightweight and strong parts with based on the knowledge we have and analysed on the tools we have. so its really a labouring tense of process and the persons involved in the manufaturing needs to know what they are doing to get the best result.
Of course we have much more complex parts. You can imagine what has to go into a simple tube, and whats nice about carbon fiber is you can vary the stengths, thichnesses in different areas with no limit. Its just how much thought you wanna put into it how much labour you wanna put into it, but it can be so optimized asnot many other materials give that kind of freedom. On the other hand not many other materials can soke up so much time in the production process and thats what makes the final part extreme and what it is at the end.